Circular Concepts and Recycling Technologies for Key Materials and Products

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1 Circular Concepts and Recycling Technologies for Key Materials and Products BASF Innovation Day SEPTEMBER 13-14, 2018, LUDWIGSHAFEN Dr. Carsten Gellermann Division Secondary Raw Materials Alzenau, Germany

2 INCREASING DEMAND FOR RESOURCES TECHNOLOGY CHANGE MEANS MATERIAL CHANGE Source: Reller, Zepf (2010)

3 FRAUNHOFER IWKS Fraunhofer Unit Materials Recycling and Resource Strategies IWKS: Founded in 2011 Staff: 85 Locations: Hanau (Hesse) Alzenau (Bavaria) Hanau Alzenau supported by State Ministries of Bavaria and Hesse

4 SCIENTIFIC TOPICS AT IWKS Alzenau Circular Management Urban Mining Biogenic Systems Hanau Magnetic Materials Energy Materials Analytics

5 MAIN TOPICS FOR CIRCULAR ECONOMY Circular Concepts Macro/Micro Logistics Innovative Separation and Sorting Technologies Generation of Concentrates (Products) Balances (LCA, LCC, etc.)

6 CIRCULAR CONCEPTS DESIGN FOR CIRCULARITY IS NECESSARY In the last 25 years the extraction of raw materials increased from 10 billion t to 15 billion t Source: Reller, Zepf (2010)

7 CIRCULAR CONCEPT RECOVERY OF STEEL FROM MEDICAL SINGLE-USE INSTRUMENTS (SRES ) These instruments usually end up in the rubbish bin and are burnt in incineration plants No recovery possible from the incineration ashes up to now

8 CIRCULAR CONCEPT RECOVERY OF STEEL FROM MEDICAL SINGLE-USE INSTRUMENTS (SRES ) Hospitals Reliable Collection and Sustainable Recovery of Material Recycling of Steel Medical Single-Use Instruments after Usage Medical Practices Reduction of Waste Reduction of Costs In Cooperation with IRED Hochschule für Design in Offenbach

9 INNOVATIVE SEPARATION AND SORTING TECHNOLOGIES Development of physical, chemical and biological methods for the recovery of raw materials Innovative separation methods (e. g. electrohydraulic fragmentation) New sorting technologies Selective recovery of raw materials by chemical transport reactions Bioleaching Mechano chemistry Aim: Reduction of process steps and development of economical process chains Bildquelle: ISC

10 INTELLIGENT GRINDING AND SORTING Bildquelle: ISC

11 SHOCK WAVE APPLICATION: EXAMPLE CIRCUIT BOARDS Before treatment After 4 Pulses After12 pulses Bildquelle: IWKS

12 SHOCK WAVE APPLICATION: SELECTED EXAMPLES CARBON FIBRE REINFORCED PLASTICS PRINTED CICUIT BOARDS SPARK PLUGS 5 mm Bildquelle: Projektgruppe IWKS

13 HIGH-TECH SORTING SYSTEM IN THE TECHNICAL CENTRE OF IWKS: EFFICIENT CIRCULAR PROCESSES BY DIGITALIZATION Input Integration of 4.0 Applications in Pilot Line Electrics/ Electronics Output Metals etc. Batteries Innovative Combination of Unique Processes to Automated Pilot Linie (Data Usage of All Aggregates for New Perspectives for Complex Material Streams)

14 SELECTIVE RECOVERY OF METALS BY CHEMICAL TRANSPORT REACTIONS Modification of the conventional chemical transport process : InCl 3(g) HCl (g) deposition condensation In 2 O 3(s), e.g. in displays T 1 T 2 Open system Volatile Product can be recovered by condensation Example: Recovery of Indium out of displays

15 RECOVERY OF METALS BY CHEMICAL TRANSPORT REACTIONS Equipment: Rotary kiln at Fraunhofer IWKS in Alzenau.

16 FUNCTIONAL RECYCLING OF ND-FE-B MAGNETS 4 APPROACHES HYDROGEN ROUTE MELT-SPINNING-ROUTE Jet-milling Mixing Pressing Sintering HDDR process 100% rec. material Bonding Mixing in crucible Addition of REM Melt-spinning Milling Pressing Addition of REM Melt-spinning Milling Mixing Pressing SINTERED MAGNET BONDED ISOTROPIC / ANISOTROPIC MAGNET HOT-PRESSED & -DEFORMED MAGNET HOT-PRESSED & -DEFORMED MAGNET

17 PILOTLINE FOR SINTERED MAGNET PRODUCTION 10 KG

18 POLYMERIC BUILDING BLOCKS FROM BIOMASS EXAMPLE: EU-PROJECT HYPERBIOCOAT

19 PILOT PLANT FOR EXTRACTION AND PRECIPITATION Extractor V= 50L, T max = 150 C, p max = 5bar Precipitation reactor V= 350L, ph adjustable Maningfold Application examples Glycan-based lacquers, inks and additives Plastics-free fertilizers Bonding agent in wood-plastic composistes (WPC) Additives for wall paint Substrates for fermentation Feedstock Examples Lignocellulose containing biomass Fibre-containing organic materials Residues from food production (pomace, skins)

20 SUMMARY Concepts for Circular Economy exist in principle Design for Circularity for the single products necessary Pilot Projects needed with respect to Design for Circularity Research Topics: Electric/electronic materials, magnets, batteries, biomass, etc. Great perspective for separation and sorting technologies

21 Dr. Carsten Gellermann Head of Division Secondary Raw Materials Fraunhofer IWKS Brentanostraße Alzenau carsten.gellermann@isc.fraunhofer.de